L-shape slotted deck board and hidden fastener system

ABSTRACT

An L-shape slotted deck board and hidden fastener system includes a decking board or plank and a hidden-type fastener device. The plank includes two generally L-shaped slots formed on a planar underside or bottom of the plank, which provide the construction member with two underside, inwards-facing shoulders or lips. The fastener is a clip-like member that includes a flat body portion and two “wing” portions on opposite edges of the body. Each wing includes a sidewall portion perpendicular to the body, as well as a lip portion attached to the sidewall and bent down inwards toward the body. The wings are complementary in shape to the slots, such that the lip and sidewall portions of the wing “hook around” the inwards-facing shoulder of the L-shaped slot. The fastener holds adjacent planks together by hooking around the planks&#39; laterally adjacent, oppositely facing slots/shoulders.

This application claims the benefit of U.S. Provisional Application Ser.No. 60/804,999, filed Jun. 16, 2006, hereby incorporated by referenceherein in its entirety.

FIELD OF THE INVENTION

The present invention relates to a deck fastener for securing deckboards together and to a supporting member and, more particularly, to afastener for securing slotted planks or deck boards to an underlyingsupport member.

BACKGROUND OF THE INVENTION

Composite deck boards or planks have become increasingly common as areplacement or alternative to traditional wood planks for outsidedecking or the like. Composite boards are made of a combination ofmaterials usually including a polymer matrix material and one or morereinforcement materials such as wood fibers, with the polymer matrixsurrounding and supporting the wood fiber reinforcement material. Thereinforcement material provides strength, workability, and dimensionalstability, while the polymer matrix material provides low-maintenancecharacteristics, durability (especially in terms of color longevity),and splinter-free wear.

Composite deck boards may be fastened to underlying support members inthe same manner as traditional wood planking, e.g., by driving afastener down through the body of the deck board. Despite improvedmechanical qualities, however, composite boards are still subject topossible splitting. Moreover, users prefer not to have fastenersprotruding above the decking surface, as may be unsightly and/or createa hazard. For example, conventional nails, even if countersunk in thefirst instance, have a tendency to work themselves above the deckingsurface over time as the planking contracts and expands due to changingweather conditions. Accordingly, various systems have been proposed forsecuring deck boards together and to underlying supports in a “hidden”manner, e.g., the fasteners do not protrude above the decking surface.

SUMMARY OF THE INVENTION

According to an embodiment of the present invention, an L-shape slotteddeck board and hidden fastener system includes at least one constructionmember (e.g., decking board or plank) and a hidden-type fastener device.The construction member includes two generally L-shaped slots formed onan underside or bottom of the construction member and extendinglongitudinally along and proximate each long edge of the constructionmember. In effect, the slots provide the construction member with twounderside, inwards-facing shoulders or lips. The fastener is a clip-likemember that includes a flat body portion and two “wing” portions onopposite edges of the body portion. Each wing includes a sidewallportion perpendicular to the body, as well as a lip portion attached tothe sidewall and bent slightly down inwards toward the body. The wingsare complementary in shape to the slots, such that the wings can bemaneuvered to engage the slots, e.g., the lip and sidewall portions ofthe wing “hook around” the inwards-facing shoulder of the L-shaped slot.The fastener holds adjacent construction members together by hookingaround the construction members' laterally adjacent, oppositely facingslots/shoulders.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will be better understood from reading thefollowing description of non-limiting embodiments, with reference to theattached drawings, wherein below:

FIGS. 1A and 1B are perspective and side elevation detail views,respectively, of a construction member with L-shaped fastener slots,according to an embodiment of the present invention;

FIGS. 2A-2D are top plan, front side elevation, perspective, and endelevation views, respectively, of a hidden-type fastener for use withthe construction members shown in FIGS. 1A and 1B;

FIGS. 3A-3G are side elevation views showing the construction membersand fasteners in use; and

FIGS. 4A and 4B are side elevation views of an alternative embodiment ofthe hidden-type fastener.

DETAILED DESCRIPTION

The present invention relates to an L-shape slotted deck board andhidden fastener system 10, which includes decking boards, planks, orother construction members 12 a, 12 b (referred to hereinafter as “deckboards”) and a hidden-type deck board fastener device 14. Typically, forconstructing a deck or similar structure, a number of deck boards 12 a,12 b and fasteners 14 will be used. In particular, the fastener 14(“fastener means”) is used for connecting (i) a first L-shape slotteddeck board 12 a to an underlying support member or joist 16 and (ii) asecond L-shape slotted deck board 12 b to the first deck board 12 a inan adjacent or lateral manner. In other words, the fastener 14 is used,in effect, to connect two deck boards to one another and both deckboards to an underlying support, in a manner in which the fastener 14lies hidden below the upper plane of the decking when secured in place.

In one embodiment of the present invention, each deck board 12 a, 12 bis a generally rectangular, generally planar member having an elongatebody 18, first and second lateral ends 20 a, 20 b (e.g., the ends areperpendicular to a longitudinal axis 22 of the board), left and rightlongitudinal sides or side walls 24 a, 24 b (e.g., the sides areparallel to the longitudinal axis of the deck board), and top and bottomlongitudinal sides 26 a, 26 b. The deck boards 12 a, 12 b may be made ofa polymer, composite, wood, or another material suitable for decking.The bottom side 26 b of the deck board 12 a, 12 b (also referred toherein as the underside of the deck board) has two generally parallel,longitudinal grooves or slots 28 a, 28 b formed therein. The slots 28 a,28 b are located proximate the left and right sides 24 a, 24 b of thedeck board, respectively, and face in opposite directions. Each slot 28a, 28 b is generally L- or J-shaped, and includes a trough-like portion36 that opens out to the deck board bottom 26 b and a rectangularextension groove 38 extending along one side of the “bottom” of thetrough in the direction of the respective side wall 24 a, 24 b. (Asshown, the top and bottom of the extension groove 38 are generallyparallel to the top and bottom sides 26 a, 26 b of the deck board, whilethe side of the extension groove is generally parallel to the left andright sides 24 a, 24 b of the deck board.) The side 40 of the troughportion 36 opposite the extension groove 38 may be curved, e.g.,provided with a radius of curvature. In effect, the slots 28 a, 28 bprovide the deck board 12 a, 12 b with two inwards-facing shoulders 42a, 42 b (“shoulder means”), opposite each of which lies the curvedtrough wall 40. The bottom portions 44 of each shoulder 42 a, 42 b maybe offset by a small longitudinal distance “X” from the remainder of thebottom side/surface 26 b of the deck board (e.g., the bottom side 26 band bottom shoulder portions 44 define parallel planes offset by aslight amount such as 0.036″), to accommodate the thickness of thefastener 14. (Here, “longitudinal” refers to a distance along an axislying perpendicular to the bottom surface plane.)

The slots 28 a, 28 b may be formed through extrusion or molding of thedeck boards, or by cutting or machining operations or the like,according to standard manufacturing methods. The slots 28 a, 28 b mayextend from end 20 a to end 20 b, or they may terminate before the ends20 a, 20 b, including a possible staggered arrangement. Typically, bothslots 28 a, 28 b will be dimensioned the same, e.g., the deck boardswill be generally bilaterally symmetric. The length and width of thedeck boards 12 a, 12 b may vary.

The fastener 14 includes a thin, flat, generally rectangular bodyportion 50 and two connection lips or “wings” 52 a, 52 b. The undersideof the body portion 50 (opposite the wings 52 a, 52 b) defines a planarunderside of the fastener. Each wing 52 a, 52 b includes arectangular-shaped sidewall 54 a, 54 b and a rectangular-shaped lipportion 56 a, 56 b. The wing sidewalls 54 a, 54 b are attached torespective side edges 58 a, 58 b of the body portion 50, and liegenerally perpendicular to the body portion, on the same side of thebody portion (e.g., the sidewalls 54 a, 54 b extend in the samedirection). The sidewalls 54 a, 54 b define the left and rightboundaries of the fastener. The lip portions 56 a, 56 b are attached tothe top edges of the wing sidewalls 54 a, 54 b at an angle A=81.50° (orthereabouts), such that the lip portions 56 a, 56 b each generally faceinwards and inclined down towards the body portion 50 by a non-0° angle“B”=(90° A). (Typical values for B range between 5° and 25°, i.e.,corresponding to an angle A between 85° and 65°.) The body 50 includestwo centrally located openings 60 a, 60 b for passing connectors, suchas screws 62 a, 62 b.

As explained in more detail below, the fastener 14 is complementary inshape to the L-shape slots 28 a, 28 b. The height of the wing sidewalls54 a, 54 b generally corresponds to the height of the flat side 64 ofthe trough 36 (e.g., the side closest to the left or right sides 24 a,24 b and generally parallel thereto), and the wing lip portions 56 a, 56b are dimensioned to fit in the extension groove 38. The openings 60 a,60 b are spaced apart from the wings by a distance such that theshoulders 42 a, 42 b fit in the space between the openings 60, 60 b andwings, as shown in FIG. 3F. As also shown in FIG. 3F, the distanceseparating the wings 52 a, 52 b, as established by the width of the bodyportion 50, is such that when two deck boards are positioned laterallytogether, the oppositely facing shoulders 42 a, 42 b of the adjacentdeck boards fit in the space between the openings and wings, with apredefined lateral space “F” lying between the deck boards.

The fastener 14 may be made of metal or some other suitably strong anddurable material, using standard manufacturing methods. For example, thefastener may be formed by stamping an appropriately shaped flat piece ofmetal or other material (e.g., the piece would be generallyrectangular), and then bending the ends of the piece in a compoundmanner to form the wings 52 a, 52 b. In this manner, the wings would beintegral with the body portion 50.

In use, with reference to FIGS. 3A-3F, a deck board 12 a is held inplace against an underlying support member 16, e.g., joist. As notedabove, the deck board 12 a is a generally rectangular, elongatedconstruction member having the L-shape slots 28 a, 28 b formed on aplanar underside thereof. The deck board may be used as decking, e.g., anumber of the deck boards are placed across the support members to forma deck. Before placing the deck board 12 a against the support 16, the“left” wing 52 a of a fastener 14 is maneuvered into the slot 28 b, suchthat the outer edge of the lip portion 56 a lies in the extension groove38. In this position, the wing 52 a effectively “curls around” theshoulder 42 b, while the rest of the fastener 14 lies extended outwardsand away from the sidewall 24 b of the deck board, as shown in FIG. 3A.The trough-like opening 36 and curved wall 40 of the slot 28 b provideclearance for the wing sidewall 54 a, for facilitating movement of thelip 56 a into the extension groove 38.

After the fastener 14 is placed in the slot 28 b, the deck board 12 a isplaced against the support 16 as shown in FIG. 3B. A screw or otherconnector 62 a is inserted through the opening 60 a and is secured inplace down into the support member 16, as indicated by arrow D. Becausethe fastener lip 56 a is bent downwards slightly, the weight of the deckboard 12 a (and/or the action of the connector 62 a in securing thefastener to the support 16) causes the lip 56 a to flex upwards slightlyin the direction given by arrow B. This in turns causes the lip 56 a toexert a downwards force in the direction of arrow C against the bottomsurface of the extension groove 38 (e.g., against the shoulder 42 b).This helps to hold the deck board 12 a securely in place.

Once the first connector 62 a has been driven into place, a second deckboard 12 b is maneuvered over the “right” wing 54 b of the fastener 14,as shown in FIG. 3C. Typically, the deck board 12 b will be oriented atan angle for positioning the leading edge of the lip 56 b in theextension groove 38 of the slot 28 a, as shown in FIG. 3D. Allowing thesecond deck board 12 b to drop into place against the support 16 causesthe lip 56 a to flex upwards slightly, as shown in FIG. 3E, holding thesecond deck board 12 b in place. Subsequently, a second connector 62 bis driven down through the second connector opening 60 b, as indicatedby the arrow E. This process is repeated for successive lateral deckboards to complete a section of decking. As should be appreciated,before attaching the second deck board 12 b over the right wing 52 b,fasteners 14 may first be disposed in the second deck board's right handslot 28 b. Also, it may be the case that a plurality of fasteners 14 areused between each successive pair of deck boards, in a spaced apartmanner down the length of the deck boards. See FIG. 3G.

Although the connectors 62 a, 62 b are shown driven into the support atan angle, the connectors 62 a, 62 b could instead be driven straightinto the support and generally flush against the fastener 14, e.g., theopenings 60 a, 60 b may be slightly tapered for countersinking purposes.

The relative dimensions and spacing of the deck boards, fasteners, slots28 a, 28 b, and wings 52 a, 52 b dictate the distance “F” (FIG. 3E)between successive deck boards once the deck boards are secured inplace. The distance F can be selected by adjusting these parameters atthe manufacturing stage. Typically, F will be selected based onaesthetic considerations, to allow enough room for passage of theconnectors 62 a, 62 b, and to allow for material expansion/contraction.

Although the fastener 14 is shown as having two openings 60 a, 60 b, oneopening could instead be provided without departing from the spirit andscope of the invention. Also, more generally speaking, two openings 60a, 60 b are more typically provided for functional symmetry (e.g., afastener can be driven through the body portion close to a deck boardshoulder regardless of which wing is engaged with the shoulder), and notnecessarily because two connectors are intended to be driven into thesupport member. In many applications, a single connector may besufficient for attaching the fastener to the underlying support.Additionally, in another embodiment, the fastener is provided without aconnector aperture. In such a case, a connector aperture is in effectmachined or otherwise provided in the field by either driving aconnector directly through the body portion (e.g., the connector formsthe aperture as it is driven through the body) or by pre-forming aconnector aperture (e.g., using a drill) and then driving a connectorthrough the newly pre-formed aperture.

Although the fastener 14 is shown as having generallyperpendicular/angled wall members, the fastener could instead be“rounded” or C-shaped, without departing from the spirit and scope ofthe invention. See, for example, the fastener 70 with C-shaped wingsshown in FIGS. 4A and 4B (not to scale). Additionally, provided thefastener and slots are complementary in shape for “hooking” the fastenerwings around the deck board slots/shoulders, the particular shape andconfiguration of the slots and wings may vary.

As used herein, the term “generally” refers to the element in questionconforming to the stated characteristic except for manufacturingtolerances, e.g., which would not affect the manner in which the L-shapeslotted deck board and hidden fastener system operates as describedherein.

As suggested above, an embodiment of the present invention may becharacterized as a construction member fastening system that includesfastener means 14, 70 and first and second elongate construction members12 a, 12 b each having an underside and at least one slot 12 a, 12 bformed in the underside, where the slot(s) defines a shoulder means 42a, 42 b for engaging the fastener means. The fastener means iscomplementary to the shoulder means for engaging the shoulder means ofboth construction members and for securing the construction members toeach other and to a support member that underlies and abuts theconstruction members.

Since certain changes may be made in the above-described L-shape slotteddeck board and hidden fastener system, without departing from the spiritand scope of the invention herein involved, it is intended that all ofthe subject matter of the above description or shown in the accompanyingdrawings shall be interpreted merely as examples illustrating theinventive concept herein and shall not be construed as limiting theinvention.

1. A system for securing construction members to an underlying support,said system comprising: an elongate construction member having anunderside and a side wall, said underside including a generally planarbottom surface and an inwards facing shoulder, wherein the shoulder isdefined by a slot formed in the underside of the construction memberproximate to the side wall; and a fastener for securing the constructionmember to an underlying support, said fastener comprising: a generallyflat body portion having at least one connector aperture and left andright, generally parallel side edges; and left and right wings attachedto the left and right side edges of the body portion, respectively, eachof said wings extending up from a top surface of the body portion andhaving a lip portion extending inwards towards a center of the bodyportion, wherein the wings are complementary in shape to the shoulder ofthe construction member for engagement therewith.
 2. The system of claim1 wherein for each of said wings, the lip portion is angled down towardsthe top surface of the body portion by a non zero-degree angle, said lipportion flexing upwards when the wing is engaged with the constructionmember shoulder and the construction member is placed against theunderlying support.
 3. The system of claim 1 wherein: the fastener bodyportion is generally rectangular; and each wing further comprises agenerally rectangular, generally flat side wall attached to a respectiveone of said left and right edges of the body portion, said wing sidewall lying generally perpendicular to the body portion and extending upfrom the top surface of the body portion, and said wing side wall havinga top edge lying generally parallel to said left and right edges of thebody portion, wherein the lip portion of the wing is attached to the topedge of the wing side wall.
 4. The system of claim 3 wherein the winglip portions are generally flat and generally rectangular.
 5. The systemof claim 3 wherein for each of said wings, the wing lip portion isangled down towards the top surface of the body portion by a nonzero-degree angle, said lip portion flexing upwards when the wing isengaged with the construction member shoulder and the constructionmember is placed against the underlying support.
 6. The system of claim1 wherein the slot is generally L- or J-shaped in lateral cross section.7. The system of claim 6 wherein the slot comprises: a first, roundedslot side wall portion extending up from the bottom surface of theconstruction member; a flat slot top surface portion extending from anend of the rounded side wall portion towards the side wall of theconstruction member, said slot top surface portion being generallyparallel to the bottom surface of the construction member; an extensiongroove extending from the slot top surface portion towards theconstruction member side wall, said extension groove being generallyrectangular in lateral cross section and having top and bottom surfacesgenerally parallel to the construction member bottom surface and a sidewall generally parallel to the construction member side wall; and asecond, generally flat slot side wall portion extending from an end ofthe bottom surface of the extension groove towards the bottom surface ofthe construction member, said second slot side wall portion beinggenerally parallel to the construction member side wall.
 8. The systemof claim 7 wherein: the construction member bottom surface includes atleast first and second generally planar sections, said first planarsection of the construction member bottom extending from an end of thesecond, flat side wall portion of the slot to the side wall of theconstruction member, and said second planar section of the constructionmember bottom extending from an end of the first, rounded side wallportion of the slot towards an edge of the construction member oppositethe side wall of the construction member; and the first and secondplanar sections of the construction member bottom surface are generallyparallel, and are spaced longitudinally apart from one another by anon-zero distance, said first planar section lying closer to a topsurface of the construction member than the second planar section bysaid non-zero distance.
 9. The system of claim 1 wherein: the fastenerbody portion is generally rectangular, and each wing of the fastenerfurther comprises a generally rectangular, generally flat side wallattached to a respective one of said left and right edges of the bodyportion, said wing side wall lying generally perpendicular to the bodyportion and extending up from the top surface of the body portion, andsaid wing side wall having a top edge lying generally parallel to saidleft and right edges of the body portion, wherein the lip portion of thewing is generally flat and rectangular and attached to the top edge ofthe wing side wall, said lip portion being angled down towards the topsurface of the body portion by a non zero-degree angle; the constructionmember slot is generally L- or J-shaped in cross section and comprises:a first, rounded slot side wall portion extending up from the bottomsurface of the construction member; a flat slot top surface extendingfrom an end of the rounded portion towards the side wall of theconstruction member, said slot top surface being generally parallel tothe bottom surface of the construction member; an extension grooveextending from the slot top surface towards the construction member sidewall, said extension groove being generally rectangular in lateral crosssection and having top and bottom surfaces generally parallel to theconstruction member bottom surface and an extension groove side walloriented generally parallel to the construction member side wall; and asecond, generally flat slot side wall portion extending from an end ofthe bottom surface of the extension groove towards the bottom surface ofthe construction member, said second side wall portion of the slot beinggenerally parallel to the construction member side wall; and each ofsaid fastener wings, in conjunction with the fastener body portion, isconfigured to hook around the construction member shoulder forengagement therewith, with the wing lip portion extending into the slotextension groove, the wing side wall extending generally along andparallel to the second, generally flat side wall portion of the slot,and the fastener body portion extending along a bottom of the shoulderand generally outwards from and perpendicular to the construction memberside wall.
 10. The system of claim 9 wherein: the construction memberbottom includes at least first and second generally planar sections,said first planar section of the construction member bottom extendingfrom an end of the second, flat side wall portion of the slot to theside wall of the construction member, and said second planar section ofthe construction member bottom extending from an end of the first,rounded side wall portion of the slot towards an edge of theconstruction member opposite the side wall of the construction member;and the first and second planar sections of the construction memberbottom are generally parallel, and are spaced longitudinally apart fromone another by a non-zero distance, said first planar section lyingcloser to a top surface of the construction member than the secondplanar section by said non-zero distance, wherein the non-zero distancecorresponds to a thickness of the fastener body portion for saidfastener body portion to lie between the construction member shoulderand the underlying support when the construction member is positionedagainst the underlying support with the second planar section of theconstruction member abutting the underlying support.
 11. A fastenercomprising: a generally flat body portion having at least one connectoraperture and left and right, generally parallel side edges; and left andright wings attached to the left and right side edges of the bodyportion, respectively, each of said wings extending up from a topsurface of the body portion and having a lip portion extending inwardstoward a center of the body portion, wherein the wings are adapted insize and shape for engagement with an inwards-facing shoulder providedin the bottom surface of a construction member, for securing theconstruction member to a support member that underlies and abuts theconstruction member, by engaging one of said wings with the shoulder anddriving a connector through the connector aperture into the underlyingsupport member.
 12. The fastener of claim 11 wherein the lip portions ofthe fastener wings are angled down towards the top surface of the bodyportion by a non zero-degree angle, said lip portions flexing upwardsaway from the body portion when the wings are engaged with theconstruction member shoulder and the construction member is placedagainst the underlying support.
 13. The fastener of claim 11 wherein:the fastener body portion is generally rectangular; and each wingfurther comprises a generally rectangular, generally flat side wallattached to one of said left and right edges of the body portion, saidside wall lying generally perpendicular to the body portion andextending up from the top surface of the body portion, and said sidewall having a top edge lying generally parallel to said left and rightedges of the body portion, wherein the lip portion of the wing isattached to the top edge of the side wall.
 14. The fastener of claim 13wherein the wings are generally flat and generally rectangular.
 15. Thefastener of claim 13 wherein the lip portions of the fastener wings areangled down towards the top surface of the body portion by a nonzero-degree angle, said lip portions flexing upwards when the wings areengaged with the construction member shoulder and the constructionmember is placed against the underlying support.
 16. A constructionmember fastening system comprising: fastener means; and first and secondelongate construction members each having an underside and a slot formedin the underside, said slot defining shoulder means for engaging thefastener means; wherein the fastener means is complementary to theshoulder means for engaging the shoulder means of both constructionmembers and for securing the construction members to each other and to asupport member that underlies and abuts the construction members.
 17. Adeck comprising: a support member; first and second elongate deck boardseach having a generally flat top surface, a generally flat bottomsurface generally parallel to the top surface, and at least one slotformed in the bottom surface, said slot defining an inwards-facingshoulder, wherein the deck boards lie laterally adjacent to one anotherand against the support member, with at least a portion of the bottomsurfaces of the deck boards abutting the support member and theinwards-facing shoulders of the deck boards lying laterally adjacent toone another but facing in opposite directions; a hidden-type fastenersecuring the deck boards to each other and to the support member, saidfastener comprising: a generally flat body portion having a connectoraperture; and first and second wings attached to opposite edges of thebody portion, each of said wings extending up from a top surface of thebody portion and having a lip portion extending inwards towards a centerof the body portion, wherein the wings are complementary in shape to thedeck board shoulders for engagement therewith, with the first wing ofthe fastener engaging the shoulder of the first deck board and thesecond wing of the fastener engaging the shoulder of the second deckboard; and a connector extending down through the connector aperture andinto the support member.
 18. The deck of claim 17 wherein the fastenerdefines a non-zero lateral distance between the deck boards.
 19. Thedeck of claim 17 wherein the lip portions of the fastener wings exert adownwards force against the shoulders, thereby pressing the deck boardsagainst the support member.
 20. The deck of claim 17 wherein: thefastener body portion is generally rectangular; and each wing furthercomprises a generally rectangular, generally flat side wall attached tothe body portion, said side wall lying generally perpendicular to thebody portion and extending up from the top surface of the body portion,and said side wall having a top edge lying generally parallel to a sideedge of the body portion where the side wall is attached, wherein thelip portion of the wing is attached to the top edge of the side wall.